Additive Manufacturing Applications at the Naval Surface Warfare Center- Philadelphia Division

Transcription

1 Additive Manufacturing Applications at the Naval Surface Warfare Center- Philadelphia Division Philip Greiner RAPID May 2017 Distribution Statement A. Distribution unlimited. Approved for Public Release.

2 Outline NSWCPD Overview ADAPT.VE Lab Overview NSWCPD AM Applications Biofouling Scanning/Printing Seal Whiskers 3D Printing Rogowski Coil Test Fixture Teletype Cartridge Obsolescence LPD17 Handle Summary

3 NSWC Philadelphia Division Philadelphia Warfare Center has a central focus on Naval Machinery Develop superior technical products and expertise by capitalizing on NSWCPD s multiple laboratories and full-scale test sites Vision: Shape the Navy s future by continuously expanding machinery systems and advantages through technical dominance. Powering Today s Fleet, Innovating Tomorrow s

4 ADAPT.VE Lab Advanced Data Acquisition Prototyping Technology Virtual Environments

5 Biofouling Laser scan biofouled panels to capture geometries of biofouling organisms to quantify roughness characteristics and to 3D print panels for hydrodynamic testing

6 Biofouling 3D Printing 1. Biofouling panel representing ship hull. Barnacles, encrusting bryozoan, and biofilm among biofouling organisms present. 2. Biofouling panel scan data captured using the Creaform MAXScan 3. 3D Model created from scan data and combined with a dovetail 3D model for 3D printing. 4. 3D Printed on Objet350 Connex3 for use in channel flow test chamber

7 Biofouling Future Work Investigate ability to print soft fouling on the Objet350 Connex3 to mimic deflection characteristics in moving water 3D Print fouling rating cheat sheets for Navy Divers to assist in assessment of fouling intensity on ship hulls

8 Seal Whiskers Proposal: Use whiskers as a sensory receptor for underwater detection of objects. 3D print representative seal whiskers using varying combinations of flexible and rigid materials to best mimic actual seal whiskers characteristics in water. Live Seal Whisker Array Permit Number: NMFS Close-up of a Sea Lion (top) and Seal (bottom) Whisker

9 Seal Whiskers 3D Printing Objet350 Connex3 3D printer used to print varying flexibility Whiskers are a combination of TangoBlack+ and VeroWhitePlus NUWC NWPT determined % rigidity may best mimic real seal whisker testing is underway

10 Seal Whiskers Future Work Design for AM will enhance seal whiskers interface with sensory equipment Scanning of a seal head will determine the whisker array

11 Rogowski Coil Test Fixture Electromagnetic field test requires a Rogowski coil sensor to sit concentric to the cable whose EM field it is reading Fixture needed within a 2 week turnaround time, making procurement of a fixture or tooling impossible

12 Rogowski Coil Test Fixture Two-piece design created in-house in 2 days Compression fit desired at interface between fixture and cable Objet350 Connex3 flexible material capability enabled compression fit without risking damage to the high voltage cable Design was iterated 3 times to optimize the compression fit First design iteration. Second design iteration. Final Design

13 Teletype Cartridge Obsolete Teletype Cartridge with no supporting documentation had OEM unable to reproduce Exhausted most of reserves and need new cartridges to support the Fleet

14 Teletype Cartridge Reverse Engineering Laser scan teletype cartridge to create 3D model Equipment used: Faro Edge Arm with ScanArm attachment All five pieces laser scanned and 3D modeled in Geomagic Design X to import into 3D printer

15 Teletype Cartridge 3D Printing First iteration of teletype cartridge printed on the Objet350 Connex3 with additional components printed on the LulzBot Taz 6 Final version of teletype cartridge printed entirely on the Objet350 Connex3 due to the fidelity requirements of various pieces

16 LPD17 Handle LPD17 electrical panel handle is a common failure point Handle is not being used as intended during the original design sailors are using it for support to enter/exit a nearby access hatch Individual handle procurement is not possible without buying the entire electrical panel

17 LPD17 Handle Reverse Engineering LPD17 Handle was laser scanned to develop the 3D model Equipment Used: Faro Edge Arm with ScanArm attachment Laser scans postprocessed in Geomagic Design X and saved as an STL for 3D printing.

18 LPD17 Handle 3D Printing LPD17 Handle has been 3D printed on the Objet350 Connex3 printer Initial prints are using VeroBlackPlus rigid material Laser scanning of 3D printed part for GD&T Future prints may require Digital ABS material for mechanical strength requirements

19 LPD17 Handle Future Work Use topology optimization software to optimize the handle design to support the increased loads experienced during underway conditions Consider various metal coating methods to enhance 3D printed model mechanical properties

20 Summary NSWCPD is the Navy s primary Warfare Center for machinery systems expertise. NSWCPD is exploring AM in various application areas Test jigs/fixtures Obsolete parts Concept models Training aids NSWCPD AM focus areas are complimented with laser metrology and virtual/augmented reality

21 Points of Contact Biofouling Seal Whiskers Rogowski Coil Fixture Teletype Cartridge LPD17 Handle Scott Storms NSWCPD Christin Murphy NUWC Newport Scott Storms NSWCPD Patrick Violante NSWCPD Phil Greiner NSWCPD

22 QUESTIONS

23 Laser Scanning Equipment Point Scanner Uses: Precision Alignments, Reverse Engineering, Large Part Q/A Accuracy: +/- 30 Ft., +/- 100 Ft. ARM w/ LLP Scanner Uses: Reverse Engineering, Q/A, Validations Accuracy: Touch Probe +/- 8 Ft. Laser Line Probe (LLP) +/- 0.5 Ft. Large Scale Scanner Uses: Large Room Scans, Shipchecks, Spatial Arrangements, & A/I Validation Portable Probe Scanner Uses: Reverse Engineering, Q/A, Validations Accuracy: +/ at 0.5 Ft. Accuracy: +/

24 Biofouling Deviation Analysis Calculation Result Average [mm] Standard Deviation [mm] RMSE [mm] Kurtosis Skewness Total Points Sampled 2,000,000 Frequency Panel #1 Deviation Frequency Distance (mm) 24